AIRCOM PIPING SYSTEM | Aircom Online Sales - ANNEX A ......pipe and fittings for compressed air 12 10 Ø25 Ø40 ACCESSORIES AIRCOM: NUT WRENCH FOR ALUMINIUM FITTINGS The AIRCOM wrench

ANNEX A

QUICK LINE ASSEMBLY INSTRUCTIONS

C025 2019

AIR IS OUR FUTURE

QUICK LINEpipe and fittings for compressed air

C O N T E N T S

Content:

• Optimum installation

• Tools required for installation

• Accessories AIRCOM: nut wrench for HR-POLYMER fittings

• Accessories: pipe insertion meter for HR-POLYMER fittings

• HR-POLYMER fittings: 16 mm - 63 mm

• HR-POLYMER fittings installation: 16 mm - 63 mm

• Accessories AIRCOM: nut wrench for ALUMINIUM fittings

• Accessories: quick body holder

• Accessories: pipe insertion meter for ALUMINIUM fittings

• ALUMINIUM fittings: 20 mm - 80 mm

• ALUMINIUM fittings installation: 20 mm - 80 mm

• ALUMINIUM fittings: 110 mm

• ALUMINIUM fittings installation: 110 mm

• ALUMINIUM fittings / installation: 168 mm

• Multilayer pipe: assembly instructions

• Threaded: valves, nipples, connectors

• Flexible pipes

• Compensation: dilation/contraction

• Installation of expansion joint flanged

• Bracketing system

• Spacing the supports

• Quick branch plug: aluminium & polymer

• Quick branch plug - installation

• Wall mount manifold aluminium

• Security wall mount manifold - installation

• Accessories: aluminium spigot

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3AIRCOM s.r.l.via Trattato di Maastricht • 15067 NOVI LIGURE (AL)Tel. + 39 0143 329502 • Fax +39 0143 358175www.aircomsystem.com • [email protected]

OPTIMUM INSTALLATIONThe AIRCOM system allows reducing installation, maintenance and system management costs.

However, the installation shall be optimally executed by authorised, qualified and specialised personnel, accurately following the provided instructions to obtain the expected reliability, security and performance results.

The lines shall always be slightly slanting towards a condensate collection and discharge point.

In order to guarantee constant maintenance of the system or a general intervention, it is advisable not to install the system underground. Provide inspection wells in case of underground installation.

Avoid conditions that may lead to excessive misalignment of the pipes. Lacking pipes alignment with the respective fittings may involve an incorrect position of the pipe end inside of the fitting and hence incorrect working conditions for the o-ring seal, and consequently possibile untightness situations.

Support the heavier accessories and equipment of a given weightmounte installed on the piping system (e.g. valves, flex some flexible hoses, flanged expansion compensators, filters etc.) using dedicated, suitable supports, to be installed arranged directly upstream and downstream of the same such accessories or equipment. If not properly supported, the static weight of such additional components or accessories may involve over the time negative consequences on the correct alignment of the piping-fitting connections and hence lead e.g. to untightness conditions.

For same reason, direct hanging of heavier objects to parts of the piping, as e.g. hose reels or similar items hanging at droplegs, should be strictly avoided too.

Provide good sealing of the threads using appropriate products in the proper quantity required. and at the right amounts. In case of doubts, we recommend to contact our Technical Service for suggestions about possible sealing solutions.

For flanged connections it is recommended to always refer to our installation instructions and to make sure availability of a correctly trimmed torque wrench to ensure the proper tightening of the bolts (please be aware that flange-to-flange connections and flanged-fitting–to–flange connections require bolt tightening at different torque values!).

All supply system maintenance or modifications shall be carried out with the system empty.

Always provide for the possibiity of disconnecting parts of the system that may be subject of maintenance, expansion or modifications thus avoiding total shutdown.

Within the Quick Line System, various options are available to this purpose thus offering high flexibility in layout:

“Sliding fittings” – similar to the usual straight fittings but without internal stop for the pipe (to be used in pairs, one sliding fitting at each end of the pipe section(s) that may require to be temporarily removed / disconnected); by proper operation they can be unscrewed and carefully slide onto the opposite pipe end, thus enablying easy removal from the side of the pipe section on which they were mounted. Reverse procedure to be followed for re-installation of the removed pipe section(s).

Flanged fittings – on larger piping sizes, pairs of flanged fittings coupled together flange-to-flange on both ends of a pipe section enable easy removal from the side of such section of pipe, after careful unscrewing of the bolts connecting the flange pairs. Please take care of respecting proper assembly procedure for flanged fittings, when reassembling together the removed part of piping.

Ball Valves and Butterfly Valves – such devices enable safe and reliable shut-off of branches of a piping network, to enable easy and safe disassembly of a part of it, so that their installation at “strategic” layout-specific places is also strongly recommended, e.g. upstream and downstream of a section or branch of piping subject to possible removal for maintenance/expansion/changes on the piping network.

4QUICK LINEpipe and fittings for compressed air

CHAMFERING CONE for the correct external and internal de-burring of the pipe

SPECIFIC WRENCH for Aircom wrench; allows efficient tightening.

PIPE INSERTION METERE allows marking the correct insertion of the pipes of any diameter

DRILL SCREWDRIVER during bracketing and during the installation of the rapid diversions.

D.16-19 mm HOLE SAW which, being crucial during the assembly of rapid diversions, allows drilling which will allow the passage of the ideal about of air required by the opening.

SCREWDRIVER during the bracketing for opening the pipe holder

ALLEN WRENCH for tightening rapid diversions

PIPE WRENCH blocks the body of the sleeve during installation

GASKET LUBRICANT allows the correct lubrication of the gaskets allowing an easier insertion of the pipe hence avoiding the risk of cutting thereof. Without oils and mineral fats, it keeps the system clean

MARKER for mounting fittings and accessories

TAPE MEASURE for measuring heights, depths, inclinations, heights etc…

PIPE CUTTER for correct vertical cutting of the pipe without forming burs

Band saw for correct cutting pipe

DE-BURRING DEVICE for de-burring the hole created during

TOOLS REQUIRED FOR INSTALLATIONFor the correct installation of AIRCOM systems it is advisable to use the following tools.


ACCESSORIES AIRCOM: NUT WRENCHFOR HR-POLYMER FITTINGS

The AIRCOM wrench allows suitably tightening the nut wrench of the fittings without causing any damage, as it usually occurs with metal pipe wrenches.

It is specifically designed for AIRCOM fittings made of plastic or aluminium material.

The AIRCOM fittings wrenches allow an accurate tightening of the fitting.

The perfect fitting of the wrenches on the ferule shall allow tightening the component and activating the safety system.

310 m

m

116 mm

Ø50

Ø40

238 m

m

82 mm

Ø25

Ø32

213 m

m

61 mm

Ø16

Ø20


ACCESSORIES: PIPE INSERTION METERThe AIRCOM “spline gauge” is an accessory required for the execution of safe mounting operations.

It allows marking on the pipe, as indicated in figures 1 and 2, the exact splining depth for all pipe measurements. Once inserted into the fitting, it will be easy to check the correct insertion depth of the pipe thus marked.

Splining marking Correct insertion depth

Fig.2Fig.1

The marking, which can be carried out using a normal marker, shall be at least flushed with respect to the ferule as indicated in the figure.

112 mm 66,8 mm 39 mm

18,45

mm

12,26

mm

217,8 mm

13,41

mm

17,84

mm

89,5 mm50 mm 78,3 mm

217,8 mm

55,2 mm 79,5 mm

217,8 mm

14,47

mm

17,15

mm

83,1 mm

70,8 mm 84,7 mm 62,3 mm

15,53

mm

16,39

mm

217,8 mm


16 mm - 63 mm HR POLYMER FITTINGS

HR Polymer d. 40 mm

16 - 20 - 25 - 32 - 40 - 50 - 63

Compressed Air

Vacuum

Inert gases

Others: please contact our technical department

16 bar

UNI-EN 1676 standard

Gasket: NBR 70 - ISO 1043

Thrust ring: Polyamide 6Standard: ISO 1043

Tightening ring: X10CrNi18-8 stainless steelStandard: UNI-EN 10088

Conical ring: Polyamide 6 - ISO 1043

ISO 7 cylindrical male gasISO 7 - NPT cylindrical male gasISO 228 cylindrical female gasNPT conical female gas

EN 13501-1:2007+A1:2009EN ISO11925-2:2010EN ISO13823:2010

Thread

MAX. OPERATING PRESSURE

DIAMETERS

TRANSPORTABLE FLUIDS

Reaction to fire

Technical features of the material

-15°C / +65°CMAX. OPERATING TEMPERATURE

99% (10 mbar approx.)MAX. VACUUM LEVEL

HR-Polymer nut

Fittings body

Clamping ring

Gasket

Push ring


8

The “QUICK LINE” Aircom system is extremely easy, quick and does not require the use of expensive and complex equipment. Just a few operations and the joint is ready for use.

16 mm - 63 mm FITTINGS INSTALLATION

1 After checking the condition of the surface of the pipe (there should be no evident scratches, abrasions, dents that could lead to leakages), perform a precise and straight cut at the desired measurement.

The cut shall be cut closest to a right angle (90° with respect to the axis of the pipe) as possible.

ALWAYS CHECK FOR THE PRESENCE OF ALL COMPONENTS AND THE CORRECT INSERTION THERE OF

Pipe cut inclination maximum tolerance

=< 7°

2 De-bur the previously executed cut at the external surface of the pipe and eliminate possible chippings and/or cut residue along the edge of the internal diameter.

Eliminate the cut residue, dust, and impurities possibly present in the pipe with the aim of avoiding future problems to the pneumatic apparatus is important.

3 Untighten the ferule, by turning it by half rotation anticlockwise: the distance between the body and the ferule shall increase.

Mark the splining depth indicated by the special spline gauge (if available) on the pipe. The mark thus obtained shall indicate the point of arrival in the internal abutment of the fitting. This will allow avoiding incomplete insertions.

AIRCOM s.r.l.via Trattato di Maastricht • 15067 NOVI LIGURE (AL)Tel. + 39 0143 329502 • Fax +39 0143 358175www.aircomsystem.com • [email protected]

9

Joints executed using the “QUICK LINE” AIRCOM systems do not require waiting times after completion; pressurisation is instantaneous.

4

Insert the pipe into the fitting and push up to the stop of the pipe at the abutment at the bottom of the splining.

AVOID THE USE OF SLIDING AGENTS, OILS, GREASES WHOSE COMPATIBILITY YOU ARE NOT SURE OF. IF NOT SURE, PLEASE CONTACT US!

7 A correct tightening of the fitting shall position the nut wrench halfway the tightening marking point.

6 Tightening shall be carried out by hand tightening up to the stop point and subsequently 180°, using a sector wrench.

Lubricate the end of the pipe and/or contact surface of the O-ring gasket using our AIRCOM lubricant so as to facilitate the operation.

5


1210

Ø25Ø40ACCESSORIES AIRCOM: NUT WRENCHFOR ALUMINIUM FITTINGSThe AIRCOM wrench allows suitably tightening the ferule of the fittings without causing any damage, as it usually occurs with metal pipe wrenches.

It is specifically designed for AIRCOM fittings made of plastic or aluminium material.

The AIRCOM fittings wrenches allow an accurate tightening of the fitting.

The perfect fitting of the wrenches on the ferule shall allow tightening the component and activating the safety system.

Ø80

Ø63Ø50

D1

D

Ø32

D1

D

Ø20


ACCESSORIES AIRCOM: QUICK BODY HOLDERThe quick grip wrenches allow an accurate and safe installation of the aluminium fittings with the following diameters: 20 mm - 25 mm - 32 mm - 50 mm.

Created specifically to hold the body of the fitting during the tightening of the ferule so as to avoid the use of inappropriate accessories that could ruin the fitting, such as the pipe wrench or pliers.

Quick grip holder for holding the aluminium fitting body Nut wrench

USING THE QUICK BODY HOLDER

Using the QLCLE wrench, clamp the screw nut and then, using the QLCPR quick grip holder, hold the body of the fitting ensuring the holder cavity coincides with the cylindrical insert of the body.

Holding the body still, tighten the ferule making sure that the fitting is tightly tightened.

HOLDING THE BODY USING QLCPR

HOLDER CAVITY ON CYLINDRICAL PART OF THE FITTING


ACCESSORIES AIRCOM: PIPE INSERTION METERThe AIRCOM “spline gauge” is an accessory required for the execution of safe mounting operations.

It allows marking on the pipe, as indicated in figures 1 and 2, the exact splining depth for all pipe measurements. Once inserted into the fitting, it will be easy to check the correct insertion depth of the pipe thus marked.

Splining marking Correct insertion depth

Fig.2Fig.1

The marking, which can be carried out using a normal marker, shall be at least flushed with respect to the ferule as indicated in the figure.

QLMISAL (lato) D. 32-63




The Quick Line Aluminium spline gauge line bears the AIRCOM ALUMINIUM indication on the side, thus making the product identifiable.

12

20 mm - 80 mm ALUMINIUM FITTINGS

Aluminium coupling d. 40 mm

Conical ring

O-ring

Aluminium body

Bush

Tightening ring

Aluminium nut

20 - 25 - 32 - 40 - 50 - 63 - 80

Compressed Air

Vacuum

Inert gases


16 bar

EN-AB 46100 Aluminium nut and bodiesUNI-EN 1676 standard




Conical ring: Polyamide 6 - ISO 1043

ISO 7 cylindrical male gasISO 7 - NPT cylindrical male gasISO 228 cylindrical female gasNPT conical female gas

EN 13501-1:2007+A1:2009EN ISO11925-2:2010EN ISO13823:2010

Thread

MAXIMUM SERVICE PRESSURE

DIAMETERS


Reaction to fire



-30°C / +80°CMAXIMUM TEMPERATURE

99% (10 mbar approx.)MAX. VACUUM LEVEL


20 mm - 80 mm FITTINGS INSTALLATION



ALWAYS CHECK FOR THE PRESENCE OF ALL COMPONENTS AND THE CORRECT INSERTION THEREOF


=< 7°



3 Untighten the ferule, by turning it by half rotation anticlockwise: the distance between the body and the ferule shall increase.

Mark the splining depth indicated by the special spline gauge (if available) on the pipe. The mark thus obtained shall indicate the point of arrival in the internal abutment of the fitting. This will allow avoiding incomplete insertions.


Joints executed using the “QUICK LINE” AIRCOM systems do not require waiting times after completion; pressurisation is instantaneous.

4


AVOID THE USE OF SLIDING AGENTS, OILS, GREASES WHOSE COMPATIBILITY YOU ARE NOT SURE OF. IF NOT SURE, PLEASE CONTACT US!

7 A correct tightening of the fitting shall position the nut wrench halfway the tightening marking point.

6 Tightening shall be carried out by hand tightening up to the stop point and subsequently 180°, using a sector wrench.

Lubricate the end of the pipe and/or contact surface of the O-ring gasket using our AIRCOM lubricant so as to facilitate the operation.

5


ISO 228 - ISO 7 cylindrical female gasNPT conical female gas

EN-AB 46100 Aluminium nut and bodiesUNI-EN 1676 standard




EN 13501-1:2007+A1:2009EN ISO11925-2:2010EN ISO13823:2010

O-ring

Aluminium body

Bush

Tightening ring

Aluminium nut

110 mm ALUMINIUM FITTINGS

Aluminium coupling d. 110 mm

110

Compressed Air

Vacuum

Inert gases


16 barMAXIMUM SERVICE PRESSURE

DIAMETERS


Thread

Reaction to fire



-30°C / +80°CMAXIMUM TEMPERATURE


Below is the process for the installation of a sleeve, valid for all components of the 110 mm line.



ALWAYS CHECK FOR THE PRESENCE OF ALL COMPONENTS AND THE CORRECT INSERTION THEREOF


=< 7°



3 Untighten the screws of the ferule, so as to perfectly insert the pipe and move it to abutment.

Mark the splining depth indicated by the special spline gauge (if available) on the pipe. The mark thus obtained shall indicate the point of arrival in the internal abutment of the fitting.

This will allow avoiding incomplete insertions.

110 mm FITTINGS INSTALLATION

AIRCOM s.r.l.via Trattato di Maastricht • 15067 NOVI LIGURE (AL)Tel. + 39 0143 329502 • Fax +39 0143 358175www.aircomsystem.com • [email protected]

17

4


AVOID THE USE OF SLIDING AGENTS, OILS, GREASES WHOSE COMPATIBILITY YOU ARE NOT SURE OF.IF NOT SURE, PLEASE CONTACT US!

6 Use a torque wrench to tighten the screws of the ferules at 30 Nm, so as to tighten the ferule correctly.

Correctly tighten the 3 screws arranged on both ferules so as to have perfect joining with the body.

Lubricate the end of the pipe and/or contact surface of the O-ring gasket using Vaseline or special sliding agents so as to facilitate the operation.

5

Use a wrench to hold the nut, so as to quicken the work and have greater tightening safety.

For further information, please contact our technical department.


For further information please contact our technical department.

CORRECT and ERRONEOUS ASSEMBLY OF THE 110 MM

Do not disassemble the fitting during the assembly operations.

Loosen the bolts slightly before pushing the end of the pipe into the fitting.

CORRECT ERRONEOUS


Aluminium nut

Tightening ring

Bushing

O-ring

Aluminium body

Erroneous position of the tightening ring

Erroneous position of the bushing

Check for the presence of the O-ring

QLMAAL168

168 mm FITTINGS INSTALLATION

QLMAAFL168

Check the gasket to make sure it is suitable for the intended service. Apply a thin coat of AIRCOM lubricant to the gasket sealinglips and exterior.

Align and bring the two pipe ends together. Slide the gasket into position and center it between the groove in each pipe end. Make sure no portion of the gasket extends into the groove in either pipe end.

The outside surface of the pipe, between thegroove and the pipe end, must be smoothand free from indentations, projections(including weld seams), and roll marksto ensure a leak-tight seal.

Position the gasket over the pipe end.Make sure the gasket does not overhangthe pipe end.

PREPARATORY STEP FOR COUPLING INSTALLATION


Insert one bolt into the housings, and thread the nut loosely onto the bolt to allow for the “swing-over” feature, as shown above.

The nut should be backed o� no further than �ush with the end of the bolt.

Using the “swing-over” feature, install the housings over the gasket. Make sure the housings’ keys engage the grooves completely on both pipe ends.

installing the housings.

Install the remaining bolt, and thread the nut �nger-tight onto the bolt.

Make sure the oval neck of each bolt seats properly in the bolt hole. Code: QLMAMARI168


22

Angle PadContact

at both pairsof bolt pads

Exaggerated for clarity

Tighten all nuts evenly by alternating sides until metal-to-metal contact occurs at the angle bolt pads. Make sure the housings’ keys engage the grooves completely on both pipe ends and that the o�sets are equal at the bolt pads. Equal, positive o�sets are necessary to ensure a rigid joint (refer to the example above). It is important to tighten all nuts evenly to prevent gasket pinching.

BAD

6. Visually inspect the bolt pads at each joint to ensure metal-to-metal contact is achieved.


For Coupling rigid, angle-bolt-pad couplings, the nuts must be tightened evenly by alternating sides until metal-to-metal c ontact occurs at the bolt pads.For Coupling rigid, angle-bolt-pad

present at the bolt pads.

openings during tightening.

personal injury, and property damage.

Install the housings over the gasket. Make sure the housings’ keys engage the grooves completely on both pipe ends.

Install the bolts, and thread a nut �nger-tight onto each bolt. For couplings supplied with stainless steel hardware, apply an anti-sieze compound to the bolt threads. Make sure the oval neck of each bolt seats properly in the bolt hole.

installing the housings.

Code: QLMAFL168


FLANGE ADAPTER INSTALLATION

QLMFLA168480D


Flange Adapters require a smooth, hard surface at the mating �ange face for proper sealing. Some applications, for which the Flange Adapter is otherwise well suited, do not provide an adequate mating surface. In such cases, a metal Flange Washer is recommended for insertion between the Flange Adapter andthe mating �ange to provide the necessary sealing surface.

A. – a �ange gasket shall be used against the serrated �ange. The Flange Washer should then be inserted between the Flange Adapter and the �ange gasket.

B. – the

Flange Washer shall be placed between the valve and the Flange Adapter.

C. etc. – the Flange Washer must be placed between the Flange Adapter and therubber-faced �ange.

D. – follow

the same arrangement as if the Flange Adapter was being mated to a serrated �ange. Refer to application “A” above.

E. Adapters – the Flange Washer must be placed between the two Flange Adapters with the hinge points oriented 90° to each other. If one �ange is not a AIRCOM Flange Adapter (i.e. �anged valve), a �ange gasket must be placed against the non-AIRCOM Flange. The Flange Washer must then be inserted between the �ange gasket and the Flange gasket.

Mating FlangeFlange Adapter

Flange GasketRaised-Face Flange GasketFlange Washer

Exaggerated for Clarity


The outside surface of the pipe, between the groove and the pipe end, must be smooth and free from indentations, projections (including weld seams), and roll marks to ensure a leak-tight seal. All oil, grease, loose paint, dirt, and cutting particles must be removed.

Check the gasket supplied to make sure it is suitable for the intended service. The color code identi�es the gasket grade. Apply a thin coat ofa AIRCOMlubricant to the gasket lips and exterior.

Install the gasket over the pipe end. Make sure the gasket is positioned properly, as shown above. The lettering on the outside of the gasket must face the �ange-adapter gasket pocket. When installed correctly, the lettering on the gasket will not be visible.


Open the hinged �ange adapter fully, and install the �ange over the gasket. Make sure the �ange key section engages the pipe groove properly.

Insert a standard, full-shank diameter assembly bolt through each of the two mating holes in the �ange adapter. This will maintain the position of the �ange in the pipe groove.

5a. Make sure the gasket is seated properly in the �ange adapter.

Flange

Proper Gasket Positioning

MatingFlange

Exaggerated for ClarityExaggerated for Clarity

GasketMarkings

GasketPosition

Closure lugs are provided for ease of installation. If nec essary, use an adjustable wrench to bring the �ange holes into alignment. This will ease insertion of the


Join the �ange adapter with the mating �ange by aligning the bolt holes.

6a. Thread standard �ange nuts �nger-tight onto the two mating bolts.

Insert a standard, full-shank diameter assembly bolt through each remaining hole in the �ange adapter/mating �ange. Thread standard �ange nuts �nger-tight onto all bolts.

Tighten the nuts evenly, as with a regular �ange assembly. Continue tightening until the �ange faces come into �rm, metal-to-metal contact or the standard, �ange-bolt torque requirement is achieved.

QUICK BRANCH PLUG INSTALLATION

QLDER168108QLDER168128QLDER168168QLDER168208QLDER168248


Proper preparation of the hole is essential for sealing and performance. Make sure the correct hole saw size is being used. Refer to the Pipe Preparation Requirements” table.

Holes MUST be drilled on the centerline of the pipe.

Ensure that a -inch/16-mm area around the hole is clean, smooth, and free from indentations and/or projections that could a�ect gasket sealing (refer to the sketch below). Remove any burrs and sharp or rough edges from the hole. Burrs and sharp edges might a�ect assembly, proper seating of the locating collar, �ow from the outlet, or gasket sealing.

The pipe around the entire circumference, within the “A” dimension shown in the sketch below, must be free from any dirt, scale, or projections that might prevent the housing from seating fully on the pipe. Refer to the Pipe Preparation Requirements” table.

A


DO NOT USE STYLE BOLTED BRANCH OULTELS ON PVC PLASTIC PIPE.


SizeHole Dimensions

inches/mmPreparation

NominalOutlet Size

inchesActual mm

Minimum HoleDiameter/Hole

Maximum

Diameterinches

mm

21.3 Outlets 38 41 89

26.9 Outlets 38 41 89

33.7 Outlets 38 41 89

42.4 Outlets 44 48 102

48.3 Outlets 51 54 102

60.3 Outlets 64 67 114

73.0 Outlets 70 73 127

Outlets 70 73 140

88.9 Outlets 89 92 140

114.3 Outlets 114 118 165

Outlets 114 118 165

† 2 x 1 ½-inch/60.3 x 48.3-mm products require a 1 ¾-inch/44-mm hole.

‡ 8 x 2-inch/219.1 x 60.3-mm products require a

A


2 ¾-inch/70-mm size hole.


Insert a bolt into the two housings. Thread a nut loosely onto the end of the bolt.

Inspect the sealing surface of the gasket to make sure no debris is present.


Rotate the lower housing so that it is positioned approximately 90° to the upper (outlet) housing, as shown above. Place the upper (outlet) housing onto the face of the pipe in line with the outlet hole cut into the pipe. Rotate the lower housing around the pipe.

3a. Make sure the locating collar engages the outlet hole properly. Check this engagement by rocking the upper (outlet) housing in the hole.

Insert the remaining bolt. Thread a nut onto the bolt �nger-tight. Make sure the oval neck of each bolt seats properly in the bolt hole.

Make sure the locating collar is still positioned properly in the outlet hole. Tighten the nuts evenly by alternating sides until the upper (outlet) housing contacts the pipe completely.


Lubricant

Lubricant, Soap-Based Solutions, Glycerin, or Silicone Release Agent

Good Good

Hydrocarbon-Based Oils, orPetroleum-Based Greases Good Not Recommended

product installation, and/or property damage.


MULTILAYER PIPE - Instruction to use the flexible pipe

Cut the pipe with the special shear. Use the calibrator tool to chamfer the pipeend and restore the correct shapeafter cutting.

Insert the internal bending spring into themultilayer pipe to start bending the pipe.

Fix the bending spring with a lanyard, that willhelp pulling out the spring from the pipeafter bending.

Bend the pipe by applying an uniformforce across the whole length of thepipe section.

Pull the bending spring out of the pipe: you willobtain the required curve with an uniform bend.NB – With the outside bending spring you shouldproceed in a similar way(slide the bending spring over the pipe!).

TO BE STRICTLY AVOIDED:A) Avoid repeated bending of the multilayer pipe at the same point (risk of damage!): for this function you should use QLFLEX.B) Avoid bending the pipe with sharp edges (risk of damage of the pipe structure!): use the appropriate bending springs.C) Do not weld, glue, punch or drill the multilayer pipe; use only dedicated mounting accessories.

Owing to its bendability, with Aircom’s multilayer pipe you will be able to easily overcome or bypassobstacles in your compressed air pipings such as pillars or corners without needing to use elbows.

THREADED: VALVES, NIPPLES, CONNECTORSThe item normally comes assembled, so as to be directly inserted into the system.

In case one intends to insert a valve or threaded element, on the system or on an aluminium connectors, proceed as follows.

INSTRUCTIONS VALID FOR THE CORRECT MOUNTING OF ALL AIRCOM THREADED ELEMENTS

1 Clean the threads accurately.

Avoid the presence of residues, burrs or impurities of various types preparing the components for the application of the DIRLOCK sealant.

2 Apply a small amount of DIRLOCK sealant on both threads.

Tighten the valve up to attaining the coupling and arrange the components in position.

3 Wait for 12 hrs for the sealant to dry completely.

The component may be operated after 12 hrs.

For an easier mounting, remove the throttle valve, tighten the valve and mount the throttle valve again.

N . B .

CLEAN THE THREADS ACCURATELY



FLEXIBLE PIPES: QLFLEXThe QLFLEX flexible pipes are made of material capable of offering an optimal compatibility with the oils of the compressors and they are conceived to guarantee minimum overall dimensions and ease of installation.

1

Actually, due to the presence of two aluminium studs at the ends thereof, the pipe may be directly connected to the Quick Line fittings installing it following the same instructions described for connecting the Quick Line to the aluminium pipe.

2

The QLFLEX flexible pipe represents the ideal solution for the compensation of dilation or contraction in the presence of:

a. level variationb. overcoming an obstaclec. connection to the compressor outletd. change of axis

3

c. connection to the compressor outlet

a. level variation

b. overcoming an obstacle

d. change of axis

RECOMMENDATIONSThe QLFLEX pipe is neither cut nor de-burredThe flexible pipe shall not be twisted for any reason whatsoever The pipe must always have a minimum curvature and never exceed the maximum curvature radius provided for Avoid passing the QLFLEX pipe on sharp edges


DILATATION / CONTRACTION COMPENSATIONWhen using QLFLEX as a dilation and contraction compensator it is recommended to follow the following instructions so as to avoid malfunctions and damages due to erroneous use of the component.

b. "OMEGA" is always directed upwards so as to avoid the formation of condensate in the pipe.

a. Obtain the so-called "LIRA" or "OMEGA" by connecting QLFLEX to two 90° elbow fittings and NEVER two sleeves aligned on the same plane.

c. It is advisable to provide a fixed point in QLFLEX with the use of an electrician collar fixed half way between the ends of the flexible pipe.

It is advisable to bracket the aluminium pipe with the special pipe wrench near the two

elbows connected to the QLFLEX.


EL INSTALLATION LENGTH

LAXIAL DILATION

ILATERAL DILATION

α°ANGULAR DILATION

min max min max +- +- α°mm

+- 30 +- 20100 150120 135

FLANGED DILATION COMPENSATORSWhen using DIRDIL as a flanged dilation and contraction compensator it is recommended to follow the following instructions so as to avoid malfunctions and damages deriving from the erroneous use of the component.

DIRDIL details:

40 Nm tightening torque for all diameters. (63 mm - 80 mm - 110 mm)Do not use solvents, adhesives, lubricants of any type for mounting

Minimum and maximum tolerance table.

Pressure and correction chart

Operatingtemperature

Allowed movement according to

the temperature

Variable pressuredepending on temperature 16 bar 12 bar 10 bar

100% 80% 60%

50° 70° 100°

PN 16 nominal pressure


INSTALLATION OF DILATION COMPENSATORS

FLANGE POSITIONEDCORRECTLY (A)

FLANGE POSITIONEDERRONEOUSLY (B)

Length EL > max.

Length EL max.<_

Bolts tightening torque for the63 mm - 80 mm - 110 mm diameters

(cross tightening is advisable) a 40 Nm

WARNING

Before mounting the DIRDIL dilation compensator, ensure that the joining surfaces are clean.

As shown in the figure, the positioning of the flanged fitting with the compensator must be accurate with the aim of ensuring the correct airflow without leakages.

Should the flange not be tightened correctly, the gasket may not be at contact with the fitting like shown in the figure.

In this case, tighten correctly and check the joints.

Consider the length during the installation of the joint, make reference to the table of maximum and minimum lengths indicated in the previous page.

INSTALLATION

1. Clean the joint surfaces.

2. Perfectly align the flanges with respect to each other.

3. Introduce the bolts after aligning the flanges:

3.1 It is advisable to use 8.8 zinc coated bolts or A 2.70 stainless steel; position the washers and bolts, tighten the entirety.

4. The bolts shall be tightened progressively uniformly in an alternating fashion according to a sequence diametrically opposite to the one indicated in the figure.

5. Tighten the bolts using a torque wrench.

Maintain the same tightening torque for the three sizes of the DIRDIL (Ø63 - Ø80 - Ø110) flanged compensator.

Tightening torque: 40 Nm.


BRACKETING SYSTEM

The pipe wrench can be fixed to any bracketing system using the same threaded bar and the relative counter-nut.

4

The bracketing of the aluminium pipe shall be carried out solely using special DIRFEM8 pipe wrench designed to allow the pipe to slide in case of possible dilations or contractions.

1 The DIRFEM8 pipe wrench was designed so as to be able to operate both in horizontal and vertical position.

Use a screwdriver to open the pipe wrench by lifting the tab to closure level.2

3 All pipe wrenches are provided, in their packaging, with an M8 hexagonal nut to be inserted, using a threaded bar, into the special seat provided in the support. In addition, self-thread screws with an expansion plug may be used in case of fixing on the wall and concrete

If necessary, DIRSPE spacers to be added to the pipe wrench base are also available. 5

SPACING THE SUPPORTSAll pipe wrenches are provided, in the packaging thereof, with an M8 hexagonal nut to be introduced, using a threaded bar, into the special seat provided in the support. In addition, self-thread screws with an expansion plug may be used in case of fixing on the wall and concrete.

The spacing of the supports is carried out according to the standard provided according to the diameter, temperature and weight of the transported fluid.It is advisable to bracket the pipe wrench as indicated in the table for a correct installation and spacing of the supports for the various pipe diameters.

2 Quick Line D 20x17 PN 16

D max

φ

The sliding supports shall not be placed at contact with fittings or other accessories with the aim of not blocking the sliding of the pipe.

Should the horizontal or vertical pipes installed at a height in the range between 0 and 250 cm from the ground, it is advisable to double the number of supports with the aim of guaranteeing an optimal constraint of the pipe to the structure.

Diametermm1620253240506380110

< 20°C2

2,53

3,54

3,53,53,53,5

30°C22

2,53

3,53333

40°C1,51,52

2,53

2,52,52,52,5

Spacing expressed in metres depending on the temperature D max (m)


The AIRCOM diversion intakes are designed to allow the end user to obtain a quick branch plug without having to cut the bearing pipe.

In addition, due to the particular design of the component the opening air intake is arranged above the condensate formation level thus guaranteeing an optimal quality of air in the opening.

The rapid diversion intakes may also be used horizontally as the traversing starting point (with the hole in the upper part of the pipe) or to obtain a condensate discharge opening (with a hole in the lower part of the pipe).

Presa aria per calata

sopra al livello di

formazione condensa

QUICK BRANCH PLUG: Aluminium and Polymer

TIGHTENING BOLT

HOLE TEMPLATE

REFERENCE NOTCH

AIR INTAKE OVER OPENING THE CONDENSATE FORMATION LEVEL


Remove the diversion intake and clean the hole using a special universal DIRVSBUNI de-burring device.5

4 Drill the pipe using the special DIRDRILL15 and DIRDRILL19 drill bits, according to the table below:

2 Accurately mark the preselected position near the reference notches.

Position the diversion according to the application needs.1

Fix the diversion intake by once again aligning the reference notches to the obtained marks.

Fasten the pin with a 5-6 Nm torque using an Allen wrench.

6

Rotate the diversion by 180° re-positioning it near the reference marks marked previously.3

QUICK BRANCH PLUG INSTALLATION:QLDERAL – QLDERPA

DIRDRILL15 - 15mm

DIRDRILL19 - 19mm

Ø25●

Summary table for the hole template in the diversions

Ø32●

Ø40

●

Ø50

●

Ø63

●

Ø80

●

Ø110

●


WALL MOUNT MANIFOLD ALUMINIUM

I

D

d1

I

D

d1

I

D

d1

D

d1

I

d1

D

I

The array of aluminium connectors is available in a wide range of models designed to meet all application needs and all compressed air supply needs.

In compliance with the safety philosophy which distinguishes the AIRCOM products, the aluminium connectors have conventional 1/2” outputs at 45° with respect to the fixing plane, so as to reduce the risk of direct ejection towards the operator.

The aluminium connectors have lateral holes with 1/2” or 3/4“ thread indispensible for the connection to FRL groups, pressure reducers, manometers.

The aluminium connectors come in 5

models and they are all conceived in the

ISO 228 aswell as NPT thread.

For further details on the aluminium connectors reference shall be made to our technical catalogue ANNEX A –Technical data sheet.


MOUNTING AND SAFETY - wall mount manifold

45°

SAFETY

DISCHARGING CONDENSATE AND NORMAL INSTALLATION

WALL MOUNT MANIFOLD MULTIPLEThe seven outputs (two lateral and five front ones) callow versatile and targeted applications on board the machine or on work benches.

The connectors have an output facing downwards at 45° with respect to the support base for ensuring possible injection of the fitting downwards thus reducing the risk of accident for the operator.

Use the QLSCI to avoid misalignment.

The aluminium connectors, just like the techno-polymer ones, are predisposed for the normal horizontal wall mounting.

The lateral outputs present on both sides also allow the installation of the connectors in series, so as to obtain useful

solutions on board the machine or for work benches.

The 1/4” condensate discharge is normally closed. In order to discharge the condensate,

drill the part using a 6 mm tip, clean and apply the special DIRVSP condensate discharge valve.


ACCESSORIES: ALUMINUM SPIGOTThe male threaded spigot is a special hollow cylinder block in aluminum alloy with a male conic gas thread for airtight couplings according ISO 7-1 at one end and a plain pipe segment of size identical to QLTUAL pipe on the other end.

D d

LL1

Male threaded Quick line spigotQLPUNMCodiceQLPUNM016038QLPUNM020048QLPUNM020068QLPUNM025088QLPUNM032108QLPUNM040128QLPUNM050168QLPUNM063168QLPUNM080248

Gr.0,0290,0350,0450,0760,1370,1820,2410,3000,734

D162020253240506380

d3/8”1/2"3/4"1"

1.1/4"1.1/2"

2”2”3”

L (in)939596

108119135141157171

L1 (in)121313161821232326

This product allows to reduce the fittings quantity in the compressor room for all the connections between the compressor and the treatment groups and relative by-passes.

All QUICK LINE fitting ends may rapidly be converted into pieces with ISO 7-1 male thread.

Compressor

Dryers

Tank

Bypass



The information contained in this document was filled according to conscience and knowledge and they meet the current state of the art requirements. The information, data and images of the Aircom Srl products contained herein are supplied without any commitment and solely for exemplification purposes. We reserve the right to perform any technical modifications even without notice. It is always recommendable to check on the actual suitability of the product for the desired application. Any reproduction, even partial, of the present document requires prior written consent from Aircom Srl.

All rights reserved.(S. E. & O.)

AIRCOM s.r.l.

Via Trattato di Maastricht15067 Novi Ligure (AL) - ITALY

Ph. +39 0143 329502 - Fax +39 0143 358175

[email protected]

AIR IS OUR FUTURE

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AIRCOM PIPING SYSTEM | Aircom Online Sales - ANNEX A ......pipe and fittings for compressed air 12 10 Ø25 Ø40 ACCESSORIES AIRCOM: NUT WRENCH FOR ALUMINIUM FITTINGS The AIRCOM wrench